Cable fabricating method and apparatus



g 1969 s. z. HAIRABEDIAN ET AL 3,459,609

CABLE FABRICATING METHOD AND APPARATUS Filed July 2, 1965 3 Sheets-Sheet1 FIG.1

FROM BRAKE EOUIPPED ATTORNEY g- 1969' B. 2. HAIRABEDIAN ETAL 3,459,609

CABLE FABRICATING METHOD AND APPARATUS 3 Sheets-Sheet 2 Filed July 2.1965 FIG. 2

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F m TI A Y K v N 9H Ill M v 0 iv 0 mm m h. m N v m U F o 0 7 .A E D A IL2 AU 5 2 Aug; '5, 1969 B. Z. HAIRABEDIAN ET AL CABLE FABRICATING METHODAND APPARATUS Filed July 2, 1965 FIG.3

3 Sheets-Sheet 5 States Patent US. Cl. 15652 11 Claims ABSTRACT OF THEDISCLOSURE A method and apparatus for fabricating fiat cable byencapsulating an array of wires between heat bondable dielectric webs.Heat is applied to the mutually facing sides of the webs by a hot bladenesting between the webs as they pass over cooling rollers and into thenip between the rollers, the blade being apertured to pass the wires ina defined configuration through the blade and into the interface betweenthe webs.

This invention relates to the art of bonding heat fusible substances,such as thermoplastic resins, and more particularly to the laminating ofsuch materials with conductor materials in the manufacture of flatcable.

The flat cable art goes back to the early days of the telegraph, when itwas found that a fiat configuration is a convenient shape for a multiplecircuit cable. More recently, the art of flat cables has become moreactive since a flat configuration lends itself easily to use withsocalled printed circuitry, facilitates identification of circuit wireswithout individual coding, and enables the design of flat transmissionlines having predetermined impedance characteristics suitable for usewith high frequencies.

For providing the prerequisite dielectric environment, as well as forprotection against short circuits and corrosion, it is preferred thatthe conductors be arranged in a generally planar array, entirely withina body or laminate of the dielectric. The prior art describes a numberof laminating techniques for manufacturing such a composite, many ofwhich techniques involve heat fusing dielectric ribbons together so asto form a tape-shaped product having the conductors encapsulated by thedielectric ribbons, at the interface between the two. In some suchprocesses the bond at the interface is made by a heat sensitive adhesivesuch as a coating of low melting-point thermoplastic previously appliedto the dielectric tapes, and in others it is made by heat softening ofthe dielectric tape materials themselves. In either case, it isnecessary during the process to deliver heat to the interface forforming the bond.

Particularly when the temperature needed for the bond is close to thedisintegration or decomposition temperature of the dielectric, thedelivery of the bonding heat becomes a difficult problem. In any case,this heat delivery difficulty becomes aggravated as laminating speedsare increased. According to one prior art technique, the laminnating iscarried out by hot rolls which are coated with a release compound towhich the softened dielectric does not adhere. According to anotherprocedure the laminating is carried out between a hot roll and a coldroll with adhesion to the hot roll being prevented by the use of atransfer belt between the hot roll and the product piece.

In accordance with the present invention, the bonding heat is applieddirectly to the interface forming surfaces as they are pressed togetherto form the laminate, the point of application of the heat being asclose to the point of bond as possible. Accordingly, in accordance withone aspect of the invention the heat is applied by a blade eleice mentwhich extends substantially to the nip of the rolls or other laminatingdevices, and is apertured to receive and pass the conductor elements ofthe cable into that According to another aspect of the invention, whichis cooperative with the first, heat sink means are provided which areapplied to the exterior of the dielectric tapes at, and preferablythroughout, the region of application of heat to the interface formingsurfaces thereof. Thus, a gradient is established from the inner to theouter surfaces of the dielectric tapes whereby the inner surfaces may beraised to a desired bonding temperature while the outer surfaces aremaintained cool enough to maintain integrity of the tapes and preventtheir adhesion to the laminating rolls.

Since the heat is applied directly where needed, little heat penetrationneed be provided and therefore the process can be speeded withoutintroduction of undue temperatures. At the same time, the employment ofthe external heat sinks makes it possible to keep the bulk of thedielectric body at a lower temperature thereby making the processparameters less critical. Finally, and importantly, since the conductorsare introduced through the heat-applying blade, a maximum of accuracy inconductor placement is assured, and the action of the heat sinksprevents later drift of the conductors from that placement. The resultis that the process facilitates quantity production of flat cable havingvery high conductor densities and meeting stringent requirements as toconductor placement, and at the same time facilitates use of dielectricmaterials in which the bonding temperatures must be closely controlled.

Accordingly, major objects of the invention are to provide improvedprocesses and machines for the production of heat fused laminates.

Another object of the invention is to provide improved processes andequipments for the production of multiconductor flat cable.

Still another object of the invention is to provide improved processesand equipment as aforesaid whereby flat cable can be made rapidly andaccurately with thermoplastic dielectric material which is subject todecomposition, disintegration, or weakening at high temperatures, evenwhere the bonding temperature required by the material is itself quitehigh.

The foregoing and other objects, features and advantages of theinvention will be apparent from the following, more particulardescription of preferred embodiments of the invention, as illustrated inthe accompanying drawings.

FIG. 1 is a somewhat schematic, partly broken away, front elevation viewof a cable laminating station of an apparatus illustrative of apreferred embodiment of the invention;

FIG. 2 is a sectional view taken about along line 22 of FIG. 1;

FIG. 3 is an enlarged sectional view taken about along line 3-3 of FIG.2;

FIG. 4 is a still further enlarged detail of a portion of FIG. 3;

FIG. 5 is a fragmentary cross section taken along line 55 of FIG. 4 andturned FIG. 6 is a fragmentary cross section of a product manufacturedin accordance with the invention; and

FIG. 7 is an idealized diagram illustrative of isotherms along thedielectric tape during laminating operation in accordance with theinvention.

The apparatus shown in FIG. 1 comprises a machine bed I10 which mounts astage or platen 12 and, via a bracket 14, a vertical slideway or tower16. The tower 16 mounts a slide 18 which is vertically adjustable, as byoperation of a knob 20, to a working position which is preciselydeterminable by a suitable gauge, indicated at 22. This adjustment,together with lateral adjustment of the stage 12, as by amicrometer-like device 24 with a cooperating gauge 26, providemechanical alignment adjustments for operation in accordance with theprocess of the invention, as will become apparent hereinafter.

In the illustrated apparatus, the laminating parts comprise a heat sinkor chill device 30 mounted on the stage 12 for cooperation with a hotblade device 32 mounted, via an insulating block 34 and a bracket 36, onthe vertical slide 18. As detailed hereinafter, chill device 30 includesthe laminating rollers by which strips or webs 38, 40 are pressed intobonded relationship around an array of wires 42 to form the finishedcable 44. As shown, the webs 38, 40 are fed from supply reels 46, 48over pulleys 50, 52 and through smoothing and tensioning clamps 54, 56.Of course the web supply reels 46, 48 may be adapted, by brake devicesthereon or otherwise, to contribute to the desired web tension, in lieuof or in addition to, the clamps 54, 56.

The conductor wire array is fed as a multiplicity of filaments, two rowsof which are seen at 58, 60, from supply reels (not shown). The wiresupply reels are provided, as is customary in the art, with drag brakedevices for providing sufficient tension in the wires to keep themstraight, as illustrated, as they are fed through the apparatus. Thewires are trained over a pulley device 62 and through an aligning comb64 and a cleansing wiper 66 to the hot blade 32-chill device 30combination for entering into the laminate thereat. The wiper 66 mayalso be adapted to contribute to tensioning of the wires.

After the laminated product has passed through the chill device orstation 30, it is conducted via a pulley device 68 through a bath ofcooling liquid 70, and thence over capstan pullies 7272 to a takeup reel(not shown). The capstan pullies are driven by a motor 73, and arearranged to grip the finished cable tightly for drawing it through theapparatus. Thus, although the laminating rollers in the chill device 30are also powered as will be explained hereinafter, it is preferred thatthe tension provided on the finished cable 44 via the capstan pullies besuflicient to at least partly overcome the drag on the dielectric websand the wires as they are fed to the laminating point. By this methodshearing stresses on the softened dielectric at that point are reduced.

As shown in FIG. 3, the chill device 30 comprises a pair of heat sinkblocks 80, 82 which journal, as indicated at 8383, a pair of laminatingrolls 84, 86. These rolls provide the pressure function or nip of thelaminating station. As indicated by the arrows in FIG. 3, the rolls 84,86 are powered for rotation in relatively opposite directions, as by amotor 88 and a gear train 98 (FIG. 2). In the preferred structure, heatexchanger means such as water conduits 92, 94 are provided. Theseconduits may be formed in shoe elements 96, 98 which are slidablyengaged in the blocks 80, 82 and are urged, as by springs 99-99, againstthe rolls 84, 86. Suitable external plumbing connections (not shown) areprovided for the conduits for feeding coolant therethrough. Thus theheat exchanger means cools the heat sink elements 80, 82 generally andparticularly the laminating rolls 84, 86 thereof.

Cooperative with the heat sink elements 80, 82 and particularly with thelaminating rolls 84, 86 thereof is the hot blade device 32 supported inoperative relationship thereto by the apparatus of FIG. 1. As seen moreclearly in FIG. 3, the hot blade device 32 comprises a pair of bladeelements 100, 102 which define a slot or channel 103 receiving the arrayof wires 42 to be encapsulated and have cooperative radiused portions104, 106 which together form an apertured tip part. This tip partreceives and passes the wires 42 and conducts them into position betweenthe webs or tapes 38, 40 at the nip of the laminating rolls 84, 86. Inthe illustrated structure, each blade comprises a shell 108 of suitablystrong and corrosion and wear resistant metal alloy, filled with a body110 of especially good heat conductor, such as silver, in whichelectrical heating elements 112 are provided.

The blades 100, 102 are attached to each other and one of the blades isattached to the insulating block 34 (FIG. 1) in any convenient mannersuch as by machine screws (not shown), whereby the blade assembly 32 ismounted by and moves as a unit with the slide 18. In one preferredconstruction shown in FIG. 3, the blades have heel portions 114, 116aligned at a small angle with the opposing surfaces 118, 120 of the heatsink blocks 80, 82 to form throat slots therewith receiving the webs 38,40. It is a feature of the invention that the outer faces of the webs38, 40 are subjected to heat sink action at and throughout (and evenbefore and after) the application of heat to the interface formingsurfaces thereof. Thus, in the illustrated apparatus, the webs 38, 40are aligned to be in direct contact with the chill surfaces 118, 120 andthe chill rolls 84, 86 while exposed first to radiant heat from theblade heels 114, 116 and then to conduction heat by direct contact withthe blade tips 104, 106.

The convergence of the elements of the cable at the nip of thelaminating rolls-84, 86 is shown in greater detail in FIG. 4, and FIG. 5shows the manner in which the tip portions 104, 106 of the bladeelements 100, 102 are formed to define precisely locating slots orapertures 113 for the wires of the array 42. As shown, the webs 38, 40are confined between the heat sink or chill rollers 84, 86 and the hotblade tip portions 104, 106, the webs being in direct contact with thehot blade tip portions 104, 106 in the region of the apex of the hotblade tip and, preferably, for a considerable distance back along theradiused tip surfaces. Thus, there is relative motion between thecontacting surfaces of the webs 38, 40 and the blade tip portions 104,106-. It has been found in practice that the webs move easily throughthe assembly without undue drag. Several of the desirable dielectricmaterials have inherently low coefficients of friction so that thisaction is not altogether unexpected.

However, in at least some of the preferred embodiments of the process,the surfaces of the webs 38, 40 facing the blade tip portions 104, 106are heated sufi'iciently so that the interface between the webs and theblade tip portions is probably lubricated by molten dielectricthroughout the area of contact. This molten or at least highly plasticcondition enables the dielectric to flow or be pressed between andaround the wires of the array 42 in the area between the end of the tipportions 104, 106 and the nip of the rolls 84, 86. In fact, it has beenfound in practice that it is desirable, at least when working withcertain materials as set forth in examples hereinafter, to set thespacing of the nip of the rolls to be slightly less than the overallthickness of the finished cable so that the dielectric material issubjected to a degree of working as it passes through the rolls. In thismanner, the tolerances in the materials and in the apparatus are takenup while insuring that there is at all times good bonding pressureapplied as the cable passes through the nip. Moreover, the degree ofworking helps insure that the dielectric settles firmly about the wireswith no voids, and that the dielectric material welds and cominglesthorough- 1y at the interface between the two webs.

The retarding forces on the webs 38, 40 in the region approaching and atthe nip of the rolls 84, 86 include the aforesaid friction on the blades100, 102, the drag at the clamps 54, 56, and the resistance at thesource reels 46, 48; those acting on the wires 42 include friction atthe wiper 66 and any brake or other resistance at the wire supply reels.These forces are balanced, in the preferred arrangement, by the sum oftractive forces applied by the capstan 72 and laminating rolls 84, 86.The capstan can be driven at a constant speed, with its rolls clampingthe cable tightly for non-slip engagement therewith, while thelaminating rolls 84, 86 may be operated in a generally constant torquemanner. The latter may be accomplished, when low coefficient of frictionmaterial is used in for the webs, by merely operating the rolls 84, 8-6at a somewhat over speeded rate and allowing them to slip on the webs.

In the example shown in FIG. 6, the cable 44 being formed may be onewhich has a geometry for defining multiple side-by-side transmissionlines A, B, C, etc., in which each transmission line comprises a signalwire 42S flanked by two ground wires 426. In order to have the desiredcharacteristic impedance as well as to facilitate isolation, eachtransmission line may be separate and the fact that a space is providedbetween the heel portions 114, 116 and the approaching webs 38, 40. InTable 1 hereinafter typical practical data include temperatures takenwithin the blade bodies which are, of course, much higher than theworking surfaces thereof but are generally proportional thereto.

Typical operating parameters for manufacture of a cable such as is shownin FIG. 6 in accordance with the invention are shown in Table 1:

TABLE I Example I Example II Example III Example IVFluroethylenepropylene (FEP fiuro- Vendor #1* Vendor #2* Vendor #3*carbon) Polyethylene Polyethylene Polyethylene Dielectric Web or Cover38,40 Material thermoplastic thermoplastic thermoplastic thermoplasticCover thickness per cover (inch) 013 012 012 0125 Cover supply tension(incl. smoothing clamp 54 or 56 tension) per cover (grams)-.- 650 600600 600 Wire 42-Silver coated oxygen free copper (Coaling ASTM Class C)(in. diam.) O07 007 007 007 Wire 42 Tension, per wire (grams) 125 125125 125 Blade temp. (taken at silver body 110 inside heel portion) F)-1, 015 630 640 600 Blade wire guide spacing (inch):

G o o nal- 023 022 022 .021 Ground to ground- 013 012 012 012 Ch ll rolltemp. F) 140 110 120 110 Chlll roll spacing at nip (i h) 023 022 023.020 Bath 70 temp. F., approx.) 00 60 60 60 Output Cable 44:

Inches per minute 60 120 66 09 Thickness (inch) .027 .023 .025 027 Wirespacing (inch):

Ground to signal 021 021 .021 021 Ground to ground 012 012 .012 012complete, and this may result in uneven spacing wherein the spacebetween transmission line sets is smaller than the space between thesignal wire and the ground wires in any given set, as illustrated. Thisprecision is enabled by the fact that the wires are located by the tipportion of the hot blade device precisely at the point in which theyenter into the cable. For further guaranteeing this alignment, it ispreferred that the wire guide comb (shown in FIG. 1 and shown also in afragmentary section in FIG. 3) have wire guiding slots in the sameconfiguration as that shown in FIG. 5, so that the wires are alreadyprealigned in the proper relationship before they pass into the heatblade device 32.

The heat gradient established across the thickness of the webs 38, 40 bythe hot blade and chill or heat sink devices 30, 32 is illustrated inidealized form in FIG. 7. The diagram of that figure is a mathematicallot assuming a blade temperature of 700 F. and a heat sink temperatureof 110 F., as indicated, and a web or tape thickness of 0.0125 inch,assuming a typical specific heat and speed of travel of the web. It willbe seen that, since the heat sink is at least co-extensive with theblade, the main body of the web is maintained at temperature below 500F. When a dielectric such as FEP flurocarbon, which has a melting pointof about 5550 F. and begins to decompose at about 750 F., is utilized,the management of temperatures in a web becomes critical. By provisionof the cooperating hot blade and heat sink devices, the bulk of the webor tape is protected in a positive manner. Moreover, since thepenetration of the heat from the blade is limited, the depth ofsoftening of the material is limited. For example, in FIG. 7, theisotherm for 550 F. is at about three mills depth and that 475 F. is atabout 4.5 mills. Assuming the material which melts at 550 F., wires 42having a diameter of seven mills are backed by fairly firm thermoplasticas they are incorporated into the laminate. This nesting serves toprevent unwanted displacement of the wires once placed in the assemblyby the hot blade device.

It should be understood that the diagram of FIG. 7 is simplified sincethere are heat gradients in the hot blade device itself. Thus, the tipportions 104, 106, because of their salient nature, are likely to besomewhat cooler than, for example, the heel portions 114, 116. In theillustrated apparatus this is compensated for by The web material inexamples 2, 3 and 4* were selfextinguishing polyethylene furnished bythree different vendors. The formulations of such materials vary withthe vendor, but the examples cited were typical of commerciallyavailable thermoplastics, having desirable physical and electricalqualities, which are useable in accordance with the invention. Inexample IV, the thermoplastic webs included a one mil thick polyestercoating on one side thereof (the sides which formed the outer surfacesof the cable).

In the foregoing table, the blade wire guide spacing differed, variouslyin the several examples, from the final wire spacing. It will be notedthat in those cases, the spacing was reduced somewhat from the bladespacing to the cable spacing. This is accomplished by stretching thecable as it passes through the nip of the laminating rolls 84, 86 in thelaminating apparatus. Since there is friction as the parts pas throughthe laminating station, this stretching is controlled by the amount oftension placed on the finished cable 46. This tension can be controlledby the difference in speed of operation between the capstan 72-72 andthe laminating ralls 84, 86. For example, the laminating rolls may beoperated at a surface speed which is approximately twice that of thecapstan rolls, and a slight increase or decrease of this ratio will tendto decrease or increase, respectively, the tension on the cable 34.

It will be understood that various controls, adjustments and otherfacilities are provided which, for clarity of illustration, have beenomitted from the drawings. Thus, in addition to external plumbing forthe heat sink means and wiring for the hot blade heater means andthermocouples and the like for maintenance of proper temperatures in thelaminating operation, there may be provided separate controls for thelaminating rolls and capstan motors 88, 73 for effecting the abovedescribed tension control. Moreover, the mount of the heat sink blocks80, 82 on the stage 12 may be adjustable. This adjustment can beutilized for controlling the laminating or chill roll spacing at the nipbetween the rolls. This dimension, at the base of the convergent throatformed by those rolls, play a role in the production of the workingduring lamination for providing a secured bond between the constituentsof the cable assembly, and, as shown in Table 1, many vary somewhataccording to the materials utilized. Other adjustments which providequality control and ease of setup operations include the verticaladjustment 20 with a hot blade device 32 and the horizontal adjustment24 of the stage 12 with respect thereto.

It will be understood that the aforedescribed method and apparatus isadaptable to variation according to the needs of the product. Forexample, although the above described stretching of the cable is aconvenient way of providing a final adjustment of the spacing of theconducting wires, some materials are not well adapted to this mode ofoperation, and it is then preferable to fix the blade wire guide spacingat virtually the final desired dimensions for the cable, and utilize aminimum of displacement-causing forces during the laminating process.Moreover, although the cooling bath 70 is desirable for insuringstability in the cable before it is threaded through the capstan orotherwise roughly handled, it will be appreciated that in certain casesthis bath might be omitted.

Other changes may be made while still preserving one or more of theseveral aspects of the invention and the attributes correspondingthereto. Thus, while the invention has been particularly shown anddescribed with reference to preferred embodiments thereof, it will beunderstood by those skilled in the art that various changes in form anddetail may be made therein without departing from the spirit and scopeof the invention.

What is claimed is:

1. In a method of laminating an array of conductors between webs of heatbondable dielectric material to form a fiat cable, the steps of:

heating directly one face of each web to at least a softening point ofsaid material while at the same time cooling the opposite face thereof,

guiding said webs into facing relationship with their heated faces injuxtaposition,

positioning said conductors in a precise array between the juxtaposionedfaces of said webs, and

pressing said webs together to encapsulate said conductors.

2. In a method of laminating a parallel array of conductors between Websof heat bondable dielectric material to form a fiat cable, the steps of:

heating one face of each web to at least the softening point of saidmaterial while at the same time cooling the opposite face thereof,

guiding said webs into facing relationship with their heated faces injuxtaposition,

positioning said conductors between the juxtaposed faces of said webs,and

stretching and pressing said webs together to work the same about saidarray and to encapsulate and finally space said conductors.

3. In a method of laminating an array of conductors between webs of heatbondable dielectric material to form a flat cable, the steps of:

heating one face of each web to the melting point of said material whileat the same time cooling the opposite face thereof,

guiding said webs into facing relationship with their heated faces injuxtaposition,

positioning said conductors between the juxtaposed faces of said webs,and

pressing said webs together to encapsulate said conductors.

4. In a method of laminating an array of conductors between webs of heatbondable dielectric material to form a flat cable, the steps of:

heating one face of each web to the melting point of said material whileat the same time cooling the opposite face thereof,

guiding said webs into facing relationship with their heated faces injuxtaposition,

positioning said conductors between the juxtaposed faces of said webs,and

stretching and pressing said webs together to Work the same about saidarray and to encapsulate and finally space said conductors.

5. Apparatus for laminating an array of wires between webs of heatbondable dielectric material to form a flat cable, comprising:

heat sink means arranged to contact one face of each web along apredetermined region thereof,

heater means operative within said regions to soften the other faces ofsaid webs While said webs are maintained intact by the cooling action ofsaid heat sinks in the same regions,

laminating pressure means for receiving said webs with said other facesin contignity, and

means for feeding said webs and said array of Wires into said laminatingpressure means with said array between the heat softened surfaces ofsaid webs for laminating the assembly into a cable,

said array feeding means being arranged to closely guide and positionsaid wires as they are fed between the web surfaces.

6. Apparatus for laminating an array of wires between webs of heatbondable dielectric material to form a flat cable, comprising:

heat sink means arranged to define a convergent throat for receivingsaid webs and guiding the webs into face-to-face proximity to eachother,

heater means operative in the region of said throat to soften theproximate faces of said Webs,

laminating pressure means providing a nip at the constricted portion ofsaid throat, and

means for feeding said webs and said array of wires into and throughsaid throat and said nip with said array between the heat softenedsurfaces of said webs so as to laminate the assembly into a cable atsaid nip,

said last means comprising capstan means engaging said cable to draw itthrough said nip, and by tension to finally space said wires in saidlaminate. 7. Apparatus for laminating a array of wires between webs ofheat bondable dielectric material to form a flat cable, comprising:

heat sink ;means including laminating roller arranged to define a throatfor receiving said webs and guiding the webs into face-to-face proximityto each other,

heater means operative in the region of said throat to soften theproximate faces of said webs,

said rollers being arranged to provide a nip at the base of said throat,

means for feeding said webs and closely guiding said wires into andthrough said throat and said nip with said wires between the heatsoftened surfaces of said webs so as to laminate the assembly into acable at said nip,

said last means comprising speed controlled capstan means engaging saidcable to draw it through said nip for establishing a tension on saidwires as they pass said nip, and

motor means for rotating said rollers in the direction of travel of saidassembly therethrough to provide a secondary feeding force on saidassembly.

8. Apparatus for laminating an array of wires between webs of heatbondable dielectric material to form a flat cable, comprising:

heat sink means including laminating rollers arranged to define a throatfor receiving said webs and guiding the webs into face-to-face proximityto each other, heater means comprising a blade means nested in saidthroat to soften the proximate faces of said webs,

said blade means being apertured to pass said Wires in a definedgeometric array into said throat,

said rollers being arranged to provide a nip at the base of said throat,and

means for feeding said webs between said blade means and said rollersand said array of wires through said apertures, into said throat andsaid nip with said array between the heat softened surfaces of said websso as to laminate the assembly into a cable at said nip. 9. Apparatusfor laminating an array of wires between webs of heat bondabledielectric material to form a fiat cable, comprising:

heat sink means comprising laminating rollers arranged to define athroat for receiving said webs and guiding the webs into face-to-faceproximity to each other,

heater means comprising a blade means nested in said throat to softenthe proximate faces of said webs,

aligning means cooperative with said blade means adapted to orient saidwires into a defined geometric array and apertured to pass said wires insaid geometric array into said throat,

said rollers being arranged to provide a nip at the base of said throat,and means for feeding said Webs between said blade means and saidrollers and said array of wires through said aligning means, into saidthroat and said nip with said array between the heat softened surfacesof said webs so as to laminate the assembly into a cable at said nip.10. Apparatus for laminating an array of wires between webs of heatbondable dielectric material to form a flat cable, comprising:

heat sink means comprising laminating rollers arranged to define athroat for receiving said webs and guiding the webs into face-to-faceproximity to each other,

heater means comprising a blade means nested in said throat to softenthe proximate faces of said webs,

said blade means being formed with a plurality of slots to pass saidwires in an array into said throat and to precisely define the wirespacing in said array as the wires enter said throat,

said rollers being arranged to provide a nip at the base of said throat,and

means for feeding said webs between said blade means and said rollersand said array of wires through said slots, into said throat and saidnip with said array between the heat softened surfaces of said webs soas to laminate the assembly into a cable at said nip. 11. Apparatus forlaminating an array of wires between webs of heat bondable dielectricmaterial to form a flat cable, comprising:

heat sink means comprising laminating rollers arranged to define athroat for receiving said webs and guiding the webs into face-to-faceproximity to each other, heater means comprising a blade means nested insaid throat to soften the proximate faces of said webs, said blade meansformed with a laterally aligned medial array of apertures to pass saidwires in a defined geometric array into said throat, said rollers beingarranged to provide a nip at the base of said throat, and means forfeeding said webs between said blades means and said rollers and saidarray of wires through said apertures, into said throat and said nipwith said array between the heat softened surfaces of said webs so as tolaminate the assembly into a cable at said nip.

References Cited UNITED STATES PATENTS 2,361,374 10/1944 Abbott 156-55 X2,539,690 1/1951 Boorn 156-178 3,068,135 12/1962 Bower 156179 3,075,8681/1963 Long 156--282 X 3,082,292 3/ 1963 Gore 174-117 3,222,237 12/1965McKelvy 156-177 FOREIGN PATENTS 208,065 3/1960 Austria.

EARL M. BERGERT, Primary Examiner T. R. SAVOIE, Assistant Examiner US.Cl. X.R.

2513 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,459 ,609 Dated August 5, 1969 Inventor) B. Z. Hairabedian et al It iscertified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

[- Column 5, line 49, "110" should read --1o0--. Column 6, line 52,"ralls" should read -rolls-; line 75, "many" should read -may. Column 7,line 37, "juxtaposioned" should read --juxtaposed--. Column 8, line 42,"roller" should read -ro1lers--.

SIGNED AND SEALED JAN 2 (197g (SEAL) Attesu EdwardM. Fletc e I WILLIAME. *SUHUYLER. R-

Commissioner of Patents Attesting Officer

